Electronic vaping device

ABSTRACT

An electronic smoking article, a method of manufacturing an electronic smoking article, and a method of achieving a smoking experience without combusting tobacco are disclosed. The electronic smoking article includes an authenticated first section, which includes an aerosol generation unit having at least one heater; an authenticated second section, which includes a power supply operable to apply voltage to the at least one heater for heating a liquid in at least a portion of the aerosol generation unit to form an aerosol; and a conductive ink circuit embedded within the first and second sections, and wherein the power supply and the aerosol generation unit are electrically connected upon joining the first and second sections, and wherein each of the first and second sections has a portion of the conductive ink circuit.

RELATED APPLICATION(S)

This is a continuation application of U.S. Application No. 16/983,045,filed Aug. 3, 2020, which is a continuation application of U.S.Application No. 16/184,449, filed Nov. 8, 2018, which is a continuationof U.S. Application No. 15/385,070, filed Dec. 20, 2016, which is acontinuation of U.S. Application No. 14/200,646, filed Mar. 7, 2014,which claims the priority and benefit of U.S. Application No.61/799,368, filed Mar. 15, 2013, the entire contents of each of whichare incorporated herein by reference.

WORKING ENVIRONMENT

Electronic smoking articles, such as electronic cigarettes and aerosolgenerators can include a capillary tube and/or capillary wick designedto deliver liquid material from a liquid reservoir to a heater. Sucharticles can be activated by a consumer drawing on a mouth piece todeliver an aerosol to the user.

Electronic smoking articles and cigarettes can consist of two pieces,for example, a first unit or piece, which includes a power supply andcontrol unit, and a second unit or piece, which includes a flavordelivery unit. Alternatively, the smoking article can be a three-pieceunit, which includes the power supply and control unit, an aerosolgenerator or aerosol generation unit, and a flavor delivery unit. Eachof these parts is optimized to yield consistent performance. Using partsthat are not optimized or made from inferior materials can deliverinferior quality output, damage other parts of the device, and damagethe reputation of the manufacturer of the smoking article. Accordingly,it would be desirable to control the use of units manufacture andsupplied by others and limit the use to genuine parts.

SUMMARY

In accordance with an exemplary embodiment, an electronic smokingarticle is disclosed, the electronic smoking article comprising: anauthenticated first section, which includes an aerosol generation unithaving at least one heater; an authenticated second section, whichincludes a power supply operable to apply voltage to the at least oneheater for heating a liquid in at least a portion of the aerosolgeneration unit to form an aerosol; and a conductive ink circuitembedded within the first and second sections, and wherein the powersupply and the aerosol generation unit are electrically connected uponjoining the first and second sections, and wherein each of the first andsecond sections has a portion of the conductive ink circuit.

In accordance with an exemplary embodiment, a method of manufacturing anelectronic smoking article is disclosed, the method comprising:embedding a first portion of a conduction ink circuit in anauthenticated first section of a smoking article, the first sectionincluding an aerosol generation unit having at least one heater; andembedding a second portion of a conduction ink circuit in anauthenticated second section, the second section including a powersupply operable to apply voltage to the at least one heater for heatinga liquid in at least a portion of the aerosol generation unit to form anaerosol.

In accordance with an exemplary embodiment, a method of achieving asmoking experience without combusting tobacco is disclosed, the methodcomprising: joining an authenticated first section of a smoking articleto an authenticated second section of the smoking article, the firstsection having a first portion of a conduction ink circuit and thesecond section having a second portion of a conduction ink circuit; andelectrically connecting a power supply and an aerosol generation unit ofthe electronic smoking article upon the formation of a completedconductive ink circuit between the first and second portions of thesmoking article, wherein the first section includes the aerosolgeneration unit having at least one heater and the second sectionincludes a power supply operable to apply voltage to the at least oneheater for heating a liquid in at least a portion of the aerosolgeneration unit to form an aerosol.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is explained below with reference to the exemplaryembodiments shown in the drawings. In the drawings:

FIG. 1 is a cross-sectional view of an electronic smoking article inaccordance with an exemplary embodiment having a conductive ink circuit;

FIG. 2 is a side view of an electronic smoking article in accordancewith an exemplary embodiment having a first portion and a secondportion, which forms a conductive ink circuit upon assembly thereof;

FIG. 3 is a side view of an electronic smoking article in accordancewith an exemplary embodiment having a first section, which includes anaerosol generation portion and a liquid supply portion, and a secondportion, which forms a conductive ink circuit upon assembly thereof; and

FIG. 4 is an end view of the first portion and the second portion of anelectronic smoking article in with an exemplary embodiment having aportion of a conductive ink circuit therein.

DETAILED DESCRIPTION

In accordance with an exemplary embodiment, conductive ink basedcircuits, which are embedded as part of an electronic smoking articleare disclosed. The conductive ink based circuits permit the operation ofthe electronic smoking article only when used with genuine or approvedparts. In accordance with an exemplary embodiment, a conductive inkcircuit can be embedded across a two-piece design or among a three-piecedesign such that the circuit, that activates the power supply and theaerosol generation unit, can be activated only when genuine parts areconnected together. In accordance with an exemplary embodiment, aconductive ink based circuit can be placed between the flavor unit (orcartridge) and aerosol generation unit or power supply unit, to activatethe article when a genuine or approved flavor unit or cartridge isconnected to the electronic smoking article.

In accordance with an exemplary embodiment, the conductive ink basedcircuit can be used to initiate pre-heating of the heater of theelectronic smoking article when the user picks up the smoking articlefor smoking. The preheating of the heater can help to reduce the latencyand improve quantity of aerosol delivered during the initial puffs. Inaddition, control measures can be incorporated to cut off the powersupply to the heater, if a puff is not detected, using a puff detector,within a set time period after the initial handling of the smokingarticle.

FIG. 1 shows an electronic smoking article 100 in accordance with anexemplary embodiment. As shown in FIG. 1 , the electronic smokingarticle 100 includes a housing 110 having a mouth end 112 and anupstream end 114. In the upstream end 114, there is provided an electricpower supply in the form of power supply 120 and electric circuitry inthe form of circuitry 122. In the mouth end 112, the smoking article 100includes a cartridge 140, a heater 144, and a capillary wick (orcapillary tube) 146. The cartridge 140, the heater 144, and thecapillary wick (or capillary tube) 146 can form the aerosol generationunit 148. In operation, the cartridge 140 delivers a liquid material 152from a liquid supply reservoir (or fluid reservoir) 150 to the capillarywick 146, which is surrounded by the heater 144. In accordance with anexemplary embodiment, one end of the capillary wick 146 extends to thecartridge 140 and the other end of the capillary wick 146 is surroundedby the heater 144. The heater 144 is connected to the electric circuitry122 via connections (not shown). The housing 110 also includes an airinlet 160, an outlet 162 at the mouth end 112, and an aerosol formingchamber 170.

In use, the liquid material 152 is supplied from the fluid reservoir 150to the capillary wick 146, which as shown in FIG. 1 is surrounded by theheater 144. When a user draws on the electronic smoking article 100 atthe air outlet 162, ambient air can be drawn through air inlet 160. Inaccordance with an exemplary embodiment, the electronic smoking article100 can include a puff detection system (not shown), which is part ofthe circuitry 122 on the upstream end 114 of the smoking article 100.The puff detection system can sense the puff and can activate the heater144 and supply the liquid material to the capillary wick 146.

The power supply 120 supplies pulses of energy to the heater 144 to heatthe end of the capillary wick 146 surrounded by the heater 144. Theliquid material 152 in the outlet end 147 of the capillary wick 146 isvaporized by the heater 144 to create a supersaturated vapor. At thesame time, the liquid material 152 being vaporized is replaced byaddition liquid material 152 moving along the capillary wick 146.

In accordance with an exemplary embodiment, the supersaturated vaporcreated is mixed with and carried in the air flow from the air inlet160. In the aerosol forming chamber 170, the vapor condenses to form aninhalable aerosol, which is carried towards the outlet 162 and into themouth of the user. The circuitry 122 and the puff detection system (notshown) are preferably programmable. In accordance with an exemplaryembodiment, the circuitry 122 and puff detection system can be used tomanage the operation of the electronic smoking article 100.

In use, once the capillary wick 146 is heated, the liquid materialcontained within a heated portion of the capillary wick 146 isvolatilized and ejected out of the outlet 147 where it expands and mixeswith air and forms an aerosol in a mixing chamber 170. The electronicsmoking article 100 also includes at least one air inlet 160 operable todeliver air to the mixing chamber 170. Preferably, the air inlets 160 tothe mixing chamber 170 can be arranged downstream of the capillary wick146 so as to minimize drawing air along the capillary and thereby avoidcooling of the capillary wick 146 during heating cycles.

In use, the volatilized material expands out of the wick 146 and intothe mixing chamber 170 where the volatized material can mix with air toform an aerosol which is then drawn through the outlet 162. In anexemplary embodiment, the at least one air inlet 160 includes one or twoair inlets 160. Alternatively, the air inlets 160 can be three, four, orfive or more. In accordance with an exemplary embodiment, the size andnumber of air inlets 160 can also aid in establishing the resistance todraw of the electronic smoking article 100.

The power supply 120 can be a Lithium-ion battery or one of itsvariants, for example a Lithium-ion polymer battery. Alternatively, thepower supply 120 may be a Nickel-metal hydride battery, a Nickel cadmiumbattery, a Lithium-manganese battery, a Lithium-cobalt battery or a fuelcell. In accordance with an exemplary embodiment, the electronic smokingarticle 100 is usable by a smoker until the energy in the power supplyis depleted. Alternatively, the power supply 120 may be rechargeable andcan include circuitry (not shown) allowing the battery to be chargeableby an external charging device. For example, the circuitry, whencharged, can provide power for a pre-determined number of puffs, afterwhich the circuitry must be re-connected to an external charging device.The electronic smoking article 100 can also include control circuitry122, which can be on a printed circuit board having a processor.

In accordance with an exemplary embodiment, the liquid material 152includes a tobacco-containing material including volatile tobacco flavorcompounds which are released from the liquid upon heating. The liquidmaterial 152 may also be a tobacco flavor containing material or anicotine-containing material. Alternatively, or in addition, the liquidmaterial 152 may include a non-tobacco material. For example, the liquidmaterial 152 may include water, solvents, ethanol, plant extracts andnatural or artificial flavors. Preferably, the liquid material furtherincludes an aerosol former. Examples of suitable aerosol formers areglycerine and propylene glycol.

In accordance with an exemplary embodiment, the aerosol generation unitincludes the liquid supply reservoir 150 and a capillary wick 146 forholding liquid received from the liquid reservoir. In accordance with anexemplary embodiment, rather than a capillary wick 146, the aerosolgeneration unit 148 can include a capillary tube (not shown) having aninlet and an outlet, the inlet being in communication with the outlet ofthe liquid supply reservoir, and the at least one heater 144 is operableto heat the capillary tube to a temperature sufficient to at leastinitially volatilize the liquid material contained within the capillarytube.

The control circuitry 122 can also include a heater activation light(not shown) at an upstream end of the smoking article 100, which isoperable to glow when the heater 144 is activated. The control circuitry122 can also include a timer operable to limit the time for which poweris supplied to the heater 144. The time-period of the electric currentsupply to the heater 144 may be pre-set depending on the amount ofliquid material 152 desired to be vaporized. For example, the controlcircuitry 122 can be programmable for this purpose.

In accordance with an exemplary embodiment, when activated, the heater144 heats a portion of the wick 146 for less than about 10 seconds, morepreferably less than about 7 seconds. Thus, the power cycle (or maximumpuff length) can range in period from about 1 second to about 10seconds.

FIG. 2 is a side view of an electronic smoking article 100 in accordancewith an exemplary embodiment having a first section 210 and a secondsection 220, which forms a conductive ink circuit upon assembly thereof.As shown, the electronic smoking article 100 includes a first section210, which includes an aerosol generation unit 211 and a second section220, which includes a power supply portion 221, which can be coupledtogether at a threaded joint (not shown) or by other convenience such asa snug-fit, snap-fit, detent, clamp and/or clasp.

In accordance with an exemplary embodiment, the aerosol generation unit211 can include the at least one heater 144, a liquid reservoir 150having a liquid material 152 therein, and a capillary wick (or capillarytube) 146. The power supply section 221 includes a power supply 120 andcircuitry 122, which is operable to apply voltage to the at least oneheater 144 for heating the liquid material 152 in at least a portion ofthe aerosol generation unit 148 to form an aerosol.

In accordance with an exemplary embodiment, a portion 212, 222 of theconductive ink circuit is embedded within the first and second sections210, 220, respectively, and the power supply and the aerosol generationunit 148 can be activated upon formation of a circuit formed byconnecting or coupling the first and second sections 210, 220 to oneanother. The portions 212, 222 of the conductive ink circuit can beembedded within the outer housing 216, 226 as shown in FIG. 2 .Alternatively, the portions 212, 222 can form part of the electricalcircuit within the smoking article 100. For example, in accordance withan exemplary embodiment, the conductive ink circuit can be formed by theconnection of the first and second sections 210, 220 to form theelectrical circuit, which provides power from the power supply 120 tothe at least one heater 144 within the aerosol generation unit.Alternatively, the conductive ink circuit formed by the connection ofthe first and second portions 212, 222 can form a circuit incommunication with the circuitry 122 of the smoking article 100, andupon establishing the conductive ink circuit, the circuitry 122 enablesthe power supply 122 to provide power to the at least one heater 144.

In accordance with an exemplary embodiment, the conductive circuit canbe formed by bringing into contact, an end portion 214, 224 of each ofthe first and second sections 210, 220 to complete the conductive inkcircuit.

In accordance with an exemplary embodiment, upon forming the circuit, apre-heating process of the at least one heater 144 of the smokingarticle 100 can be initiated. In addition, the pre-heating of thesmoking article 100 can also be configured based on detection of a userpicking up the smoking article 100. For example, a smoking article 100having a conductive ink circuit on an outer portion thereof upondetection of being handled by a user, the smoking article 100 can begina pre-heating process, which can reduce the latency and improve quantityof the aerosol delivered during the initial puffs.

In accordance with an exemplary embodiment, the first section 210 andthe second section 220 each comprise an outer cylindrical housing 216,226 extending in a longitudinal direction, and wherein each of the outercylindrical housings has a portion 212, 222 of the conductive inkcircuit embedded therein.

FIG. 3 is a side view of an electronic smoking article 100 in accordancewith an exemplary embodiment having a two-piece first section 210, whichincludes an aerosol generation portion 240 and a liquid supply portion230, and a second portion 220, which forms a conductive ink circuit uponassembly thereof. In accordance with an exemplary embodiment, the firstsection 210 includes an aerosol generation portion 240 and a liquidsupply portion 230, and wherein the conductive ink circuit 242, 232 isembedded within an outer cylindrical housing 241, 231 of the aerosolgeneration portion 240 and the liquid supply portion 230. The at leastone heater 144 housed within the aerosol generation portion 240 isactivated only when the conductive ink circuit is formed by connectingthe aerosol generation portion 240, the liquid supply portion 230 andthe second portion 220, and wherein the aerosol generation portion 240,the liquid supply portion 230 and the second section 210 each has aportion 242, 232, 222. 224, 234, 236, and 244 of the conductive inkcircuit and upon assembly thereof forms the circuit.

In accordance with an exemplary embodiment, for example, the conductiveink circuit can be embedded in parts manufactured by an authorizedmanufacturer of the first and second sections 210, 220 for a two-pieceelectronic smoking article 100, or an authorized manufacturer of theaerosol generation portion 240, the liquid supply portion 230, and thesecond portion, for a three-piece electronic smoking article 100. Forexample, if a user attempts to place a non-authorized part within thesmoking article 100, the smoking article 100 will not function. Forexample, in the absence of the conductive ink circuit, the power supply120 will not provide power to the heater 144.

FIG. 4 is an end view of the first portion 210 and the second portion220 of an electronic smoking article in with an exemplary embodiment,wherein each of the first and second portions 210, 220 includes aportion of a complete conductive ink circuit therein. As shown in FIG. 4, the conductive ink circuits 212, 222 can be embedded within the endportions 213, 223, and upon connecting the first and second portions210, 220 of the smoking article 100, the conductive ink portions 212,222 complete the circuit. In accordance with an exemplary embodiment,the conductive ink circuits 212, 222 can be elongated line, pattern orcompletely covered area forming a contact and/or contact pads.

The electronic smoking article 100 is preferably about the same size asa conventional cigarette. In some embodiments, the electronic smokingarticle 100 can be about 80 mm to about 88 mm long and about 7 mm toabout 8 mm in diameter. The outer cylindrical housing 110 of theelectronic smoking article 100 may be formed of any suitable material orcombination of materials. Examples of suitable materials include metals,alloys, plastics or composite materials containing one or more of thosematerials, or thermoplastics that are suitable for food orpharmaceutical applications, for example polypropylene,polyetheretherketone (PEEK), ceramic, and polyethylene.

In an exemplary embodiment, the heater 144 includes a coil of wire atleast partially surrounding the capillary wick 146. In an exemplaryembodiment, the heater 144 is a metal wire and/or a metal alloy wire.The heater 144 can be a coil, which can extend fully or partially alongthe length of the capillary wick 146.

The electronic smoking article 100 can include a puff indicator (notshown) for indicating when the heater 144 is activated. In theembodiment in which the electric circuitry includes a sensor to detectair flow indicative of a user taking a puff, the indicator, such as anLED, may be activated when the sensor senses air flow indicative of theuser taking a puff. In the embodiment in which the electric circuitryincludes a manually operable switch, the indicator may be activated bythe switch. In addition, control measures can be incorporated to cut offthe power supply to the heater if a puff is not detected by a puffdetector, within a set time period after the initial handling of thesmoking article.

When the word “about” is used in this specification in connection with anumerical value, it is intended that the associated numerical valueinclude a tolerance of ±10% around the stated numerical value. Moreover,when reference is made to percentages in this specification, it isintended that those percentages are based on weight, for example, weightpercentages.

Moreover, when the words “generally” and “substantially” are used inconnection with geometric shapes, it is intended that precision of thegeometric shape is not required but that latitude for the shape iswithin the scope of the disclosure. When used with geometric terms, thewords “generally” and “substantially” are intended to encompass not onlyfeatures, which meet the strict definitions, but also features, whichfairly approximate the strict definitions.

It will now be apparent that a new, improved, and nonobvious electronicsmoking article has been described in this specification with sufficientparticularity as to be understood by one of ordinary skill in the art.Moreover, it will be apparent to those skilled in the art that numerousmodifications, variations, substitutions, and equivalents exist forfeatures of the electronic smoking article, which do not materiallydepart from the spirit, and scope of the invention. Accordingly, it isexpressly intended that all such modifications, variations,substitutions, and equivalents, which fall within the spirit and scopeof the invention as defined by the appended claims, shall be embraced bythe appended claims.

What is claimed is:
 1. An electronic smoking article comprising: a first housing of the electronic smoking article including a first portion of a conductive ink circuit embedded in the first housing; a second housing of the electronic smoking article including a second portion of the conductive ink circuit embedded in the second housing, the second housing configured to removably connect to the first housing, and the second portion of the conductive ink circuit configured to removably connect to the first portion of the conductive ink circuit; and a third housing of the electronic smoking article including a third portion of the conductive ink circuit embedded in the third housing, the third housing configured to removably connect to the second housing, the third portion of the conductive ink circuit configured to removably connect to the second portion of the conductive ink circuit.
 2. The electronic smoking article of claim 1, further comprising: a reservoir configured to contain a liquid; and at least one heater configured to generate an aerosol from the liquid.
 3. The electronic smoking article of claim 2, wherein the at least one heater is included in the first housing; and the reservoir is included in the second housing.
 4. The electronic smoking article of claim 2, further comprising: a wick in fluid communication with the reservoir, the wick configured to supply the liquid for the at least one heater.
 5. The electronic smoking article of claim 4, wherein the wick is further configured to supply the liquid for the at least one heater when the first housing and the second housing are connected.
 6. The electronic smoking article of claim 2, further comprising: a power supply configured to provide energy to the at least one heater; and control circuitry configured to control activation of the electronic smoking article.
 7. The electronic smoking article of claim 6, wherein the power supply and the control circuitry are included in the third housing.
 8. The electronic smoking article of claim 6, wherein the control circuitry is further configured to enable the power supply to provide energy to the at least one heater when the first portion, the second portion, and the third portion of the conductive ink circuit are connected.
 9. The electronic smoking article of claim 6, wherein the control circuitry is further configured to not enable the power supply to provide energy to the at least one heater when the first portion, the second portion, and the third portion of the conductive ink circuit are not connected.
 10. The electronic smoking article of claim 6, wherein an electrical circuit is formed between the power supply and the at least one heater when the first portion, the second portion, and the third portion of the conductive ink circuit are connected.
 11. An electronic smoking article comprising: a first portion of a conductive ink circuit; a second portion of the conductive ink circuit, the second portion of the conductive ink circuit configured to removably connect to the first portion of the conductive ink circuit; and a third portion of the conductive ink circuit, the third portion of the conductive ink circuit configured to removably connect to the second portion of the conductive ink circuit, and the first portion, the second portion, and the third portion form an electrical circuit between at least one heater and a power source when the first portion, the second portion, and the third portion are electrically connected.
 12. The electronic smoking article of claim 11, further comprising: a reservoir configured to contain a liquid; and the at least one heater configured to generate an aerosol from the liquid.
 13. The electronic smoking article of claim 12, wherein the first portion is electrically connected to the at least one heater; and the second portion is electrically connected to the reservoir.
 14. The electronic smoking article of claim 12, further comprising: a wick in fluid communication with the reservoir, the wick configured to supply the liquid for the at least one heater.
 15. The electronic smoking article of claim 14, wherein the wick is further configured to supply the liquid for the at least one heater when the first portion and the second portion are electrically connected.
 16. The electronic smoking article of claim 12, further comprising: a power supply configured to provide energy to the at least one heater; and control circuitry configured to control activation of the electronic smoking article.
 17. The electronic smoking article of claim 16, wherein the power supply and the control circuitry are electrically connected to the third portion.
 18. The electronic smoking article of claim 16, wherein the control circuitry is further configured to enable the power supply to provide energy to the at least one heater when the first portion, the second portion, and the third portion of the conductive ink circuit are electrically connected.
 19. The electronic smoking article of claim 16, wherein the control circuitry is further configured to not enable the power supply to provide energy to the at least one heater when the first portion, the second portion, and the third portion of the conductive ink circuit are not electrically connected.
 20. The electronic smoking article of claim 16, further comprising: at least one first housing, the at least one first housing including the first portion and the second portion; and at least one second housing, the at least one second housing including the third portion. 